Light woven sheet

ABSTRACT

A woven sheet that is lightweight and breathable, while also being a durable, long-lasting type. The lightweight woven sheet comprises a dynamic grid construction that allows moisture vapor to escape while preserving durability of the sheet. The sheet includes a first section including a first type of weave having a first grid pattern and a second section including a second type of grid having a second grid pattern. The first weave is an open-weave, which makes the sheet breathable and lowers the overall weight of the sheet, while the second weave is a plain weave that provides durability to the overall sheet.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 63/073,413 filed on Sep. 1, 2020. The above identified patent application is herein incorporated by reference in its entirety and no part of the application has been disclaimed.

TECHNICAL FIELD

The present disclosure relates generally to the field of woven fabrics, and the products made therefrom.

BACKGROUND

Heat retention in the bedding environment is a crucial topic in the bedding and mattress industries, especially with the growth of the foam mattress sector. While this issue has been studied in depth for mattresses, innovations in sheeting and bedding construction has been limited. Yet thermal regulation during sleep is vital to getting a good night's rest, as temperature is one of the main reasons for waking up during the night. Many products that are designed to maintain body temperature only focus on fiber type, while the construction of the fabric itself is fairly conventional. Fiber type can influence cooling, but if the construction is not open and breathable, the fabric will trap heat no matter what fiber.

A few brands have marketed cooling sheets but have not achieved cooling through weight and construction of the fabric. Instead, these brands typically approach improvements from a fiber blend perspective. For example, one brand claims cooling through the use of synthetic fibers. This is a debatable approach since synthetic fibers may feel cool to the first touch but will actually warm up to body temperature over time.

Moreover, the allure of so-called “high quality” resulting from high thread count sheeting may actually have a negative effect on temperature. While high thread count may create a more durable sheet, the higher thread count packs in more threads per inch of fabric, creating less breathability and a hotter sleeping sheet.

Prior art from other industries, such as the outdoor or activewear apparel industry, may be analogous to this density-focused textile technology. Most brands approach cooling from a fiber choice perspective, but do not address construction of the sheet itself.

SUMMARY

The objective is to provide a woven sheet that is lightweight and breathable, while also being a durable, long-lasting type. A bedsheet made of this type of lightweight woven fabric comprises a dynamic (varying) grid construction that allows moisture vapor to escape the bedding environment and keep the sleeper comfortable and asleep throughout the night while preserving durability of the fabric. The bedsheet made out of the lightweight woven fabric described herein approaches cooling holistically from both fiber type and construction perspectives.

For example, a combination of light weight, low thread count, and high tear strength in a dynamic dobby grid construction provides a very breathable, soft, and durable sheet—optimal for temperature regulation during sleeping. Other brands use typical Percale or Sateen constructions and generally have not approached fabrics in this weight class, typically due to durability. This resulting product is actually more durable than other sheeting due to the dynamic grid construction. The sheet made out of the lightweight woven fabric of the present invention may be branded as a HYPERLIGHT™ sheet.

The invented lightweight woven sheet can be successfully used for many other bedding items, such as pillowcases, duvet covers, mattress toppers, etc.

The invented woven sheet comprises a first section having a 2-by-2 dobby weave and a second section having a 1-by-1 plain weave, the first section contacting the second section, wherein an area of first section is greater than an area of the second section; and wherein the first section and the second section both comprise a lyocell fiber.

The invented woven sheet comprises a first section including a first weave having a first grid pattern, and a second section including a second weave having a second grid pattern. The second section is coupled to the first section, wherein an area of first section is greater than an area of the second section, and wherein the first grid pattern is less dense than the second grid pattern. The first weave contributes most to an air permeability characteristic of the woven sheet, and the second weave contributes most to a durability characteristic of the woven sheet. The second weave can be a plain weave having, and second grid pattern can be a 1-by-1 grid pattern. The first weave can be a dobby weave, and the first grid pattern can be a 2-by-2 grid pattern. The air permeability characteristic of the first section can be about 304 cubic feet per minute or greater. The weight characteristic of the woven sheet cane be about 85 grams per square meter or less. The first section may comprise a plurality of geometric patterns, such as a first geometric pattern and a second geometric pattern. The first and second sections may be directly connected, and both may comprise a lyocell fiber. The woven sheet may use the same yarn in both warp and weft directions, or it may use different yarns.

The invention includes a method for making a woven sheet comprising the steps of (i) weaving a first section using a first weave having a first grid pattern and (ii) and weaving a second section using a second weave having a second grid pattern, the second section coupled to the first section, wherein the first section has a greater area then the second section, the first grid pattern is more open than the second grid pattern, such that the first weave contributes most to air permeability of the woven sheet, while the second weave contributes to durability of the sheet.

BRIEF DESCRIPTION OF THE DRAWINGS

The illustrated embodiments of the subject matter will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and processes that are consistent with the subject matter as claimed herein.

FIG. 1 shows a lightweight, breathable woven sheet in accordance with an embodiment of the invention;

FIG. 2 shows a lightweight, breathable woven sheet in accordance with another embodiment of the invention;

FIG. 3 is a more detailed view of a portion the lightweight, breathable woven sheet in FIG. 2.

FIG. 4 is a set of test results showing certain properties of a lightweight, breathable woven sheet in accordance with an embodiment of the invention;

FIG. 5 is a set of test results showing certain other properties of a lightweight, breathable woven sheet in accordance with an embodiment of the invention;

FIG. 6 is a set of test results showing certain additional properties of a lightweight, breathable woven sheet in accordance with an embodiment of the invention;

DETAILED DESCRIPTION

The present invention provides a woven sheet that is lightweight and breathable, while also being a durable, long-lasting type. The lightweight woven sheet of the present invention may use yarn made out of lyocell fiber, which is a type of rayon fiber. The US Federal Trade Commission's regulations state that rayon is “a manufactured fiber composed of regenerated cellulose, as well as manufactured fibers composed of regenerated cellulose in which substituents have replaced not more than 15% of the hydrogens of the hydroxyl groups.” The regulation further states that “[w]here the fiber is composed of cellulose precipitated from an organic solution in which no substitution of the hydroxyl groups takes place and no chemical intermediates are formed, the term lyocell may be used as a generic description of the fiber.” 16 CFR § 303.7(d) (2020).

One brand of lyocell fiber that can be used in the present invention is 100% TENCEL® yarn from Lenzing AG. TENCEL® cellulosic fibers are of botanic origin and have natural comfort, strength, efficient moisture absorption and gentleness to skin.

Shown in FIG. 1 is a schematic drawing of an embodiment of the lightweight woven sheet 100 of the present invention having a grid construction 110. Since lighter fabrics tend to tear, this grid construction reinforces the sheet from tearing. This produces an overall superlight, drapey sheet.

Specifically, the sheet sample 100 in FIG. 1 comprises a dynamic (variable) grid construction 110, combining a plain weave 120 pattern with an open dobby weave 130 pattern. The latter creates areas of breathability and the former creates areas of reinforcement. The fabric is woven at a low thread count using natural, moisture absorbing fibers to encourage breathability and moisture vapor transport.

FIG. 2 is a schematic drawing of another embodiment of the lightweight woven sheet 200 of the present invention. The 1×1 plain weave section/segment (also called tabby weave, linen weave or taffeta weave) shown as 210 is the most basic of three fundamental types of textile weaves (along with satin weave and twill). It is strong and hard-wearing and is used for fashion and furnishing fabrics. In plain weave cloth, the warp and weft threads cross at right angles, aligned so they form a simple crisscross pattern. Each weft thread crosses the warp threads by going over one, then under the next, and so on. The next weft thread goes under the warp threads that its neighbor went over, and vice versa. Balanced plain weaves, such as the 210 segment (section), are fabrics in which the warp and weft are made of threads of the same weight (size) and the same number of ends per inch as picks per inch. A balanced plain weave can be identified by its checkerboard-like appearance. It is also known as one-up-one-down weave or over-and-under pattern. This results in a matte finish with a cool, crisp feel.

The 2×2 basket weave section/segment (or matt weave) shown as 220 is not tightly woven and is often produced on a dobby loom. This creates a dobby weave, which is characterized by small, repeating geometric patterns and extra texture in the cloth. Depending on the thread count, fiber and other properties, dobby weave results in breathable open constructions. This leaves open holes that allows breathability through physical construction.

This type of weave is constructed by extending the plain weave in warp and weft directions at the same time so that two or more threads work alike in both directions. In this weave, the same size of squares appears on both sides of the fabric showing the same number of warp and weft yarns on front and back of the fabric. This weave requires a minimum of two heald frames.

In FIG. 2, the 2×2 basket weave creates two separate geometric patterns of breathable area.

FIG. 3 shows an enlarged view of an area identified by reference 230 in FIG. 2. Here, segment 310 shows an enlarged view of the 1×1 plain weave segment (of FIG. 2), comprising the higher density segment of the presently shown pattern. In turn, segment 320 shows an enlarged view of the 2×2 basket weave segment (of FIG. 2), which is not as tightly woven as segment 310 (i.e., it is a lower density segment then segment 310). The created dobby weave generates extra texture in the cloth, and attractive geometric patterns which could be paced as shown in segments 320 and 330, for example, leading to higher sheet breathability in areas 320 and 330 of the sheet.

This invention provides numerous advantages: the less tightly woven sections of the sheet reduce the overall weight of the material per unit area (e.g., square foot or square meter). In addition, the less tight weaves increase breathability of the fabric. The lightweight and breathable characteristics of the sheet make is perfect for bedding applications, such as bedsheets, duvet inserts, quilts, pillows, pillowcases, mattress covers, and other bedding products.

The invented sheet allows it to be over 6 times more breathable than a typical 1×1 percale fabric, while also improving upon the tear and breaking strength. (Percale is a type of weave used to make sheets, towels, and other types of bedding.) Despite its relatively low thread count, the quality and durability of the sheet is maintained.

Features of this lightweight, breathable woven sheet may include:

-   -   Yarn size may be 40×40, 60×60 or 80×80.     -   The weight of approximately 85 g/m², which is about 30 to 50         g/m² lighter than conventional sheeting fabrics.

Alternatives of 100% lyocell for this lightweight woven sheet include the following fabrics: Organic Cotton/Conventional Cotton/Recycled Cotton; Linen; Hemp; Recycled Polyester/Conventional Polyester; Recycled Nylon/Conventional Nylon; Wool; Cashmere; Alpaca; or blends of 2 or more of the above fibers.

Table 1 below shows a comparison and illustrates the advantages of the present invention over the prior art (such as OLD SUPIMA PERCALE, SATEEN, PERCALE). As can be seen from the table, the invention implemented achieves a significantly lighter weight than the prior art, combined with a higher breathability.

TABLE 1 BREATHABILITY THREAD WEIGHT (Cubic Feet per NAME CONTENT CONSTRUCTION COUNT (g/m²) Minute) OLD 100% 1 × 1 Percale 400 TC 128 16 SUPIMA Supima 2/80 × 2/80 PERCALE Cotton [2-ply 80's yarn] 110 warp threads × 90 weft threads SATEEN 100% 3 × 1 Sateen 276 TC 116 93.7 GOTS 60 × 60 yarn Organic 185 warp threads × Cotton 91 weft threads PERCALE 100% 1 × 1 Percale 300 TC 90 30 Organic 80 × 80 yarn Cotton 185 warp threads × 115 weft threads Present 100% Dobby Check 202 TC 85 304 Invention Tencel 60 × 60 yarn 108 warp thread × 94 weft threads

FIG. 4 discloses the low shrinkage and good shagging resistance of the fabric made according to the present invention when tested according with the AATCC 135-18t and ASTM D5362-13 (R2018) specifications, respectively, both of which are incorporated herein by reference. As can be seen from FIG. 4, for the first 1-5 wash cycles, the invented sheet shows very slight shrinkage, both lengthwise and width-wise. However, after 5 and more wash cycles, there is no further shrinkage. As a result, the shrinkage becomes limited to 5.0% length-wise, and at 2.0% width-wise.

FIG. 4 also shows that the invented sheet can achieve an average shagging grade of 3.5 in both front and back surfaces.

FIG. 5 discloses the good air permeability and excellent piling resistance of the lightweight breathable sheet made according to the present invention (with yearn number tested per ASTM D1059-17) when tested according with the ASTM D737-18 (permeability), ASTM D4970-16E3 (piling resistance), and ASTMD3512-16 (piling resistance) specifications, each of which is incorporated herein by reference. For example, the invented sheet can maintain an average piling grade of 4.0 even after 1000 cycles per the ASTM D4970-16E3 specification, and a piling grade of 4.5 after 60 min. per the ASTM D3512-16 specification, mining the fabric's piling characteristic is between slight piling and no piling.

FIG. 6 discloses the tearing strength and breaking strength of the lightweight breathable sheet made according to the present invention when tested according with the ASTM 2261-13(R2017)E1 (tearing strength) and ASTM D5034-09(R2017) (breaking strength). (The thread-count of 202, based on average ends and average picks per D3775-17e1 and wight, according to ASTM D3776-09A(R2017) Option C, of 85 g/square meter.) Each of the above specification is incorporated herein by reference. FIG. 6 shows the tearing strength of the sheet being 10.5 lbs in the warp direction and 10.3 lbs in the weft direction. The Figure also shows the braking strength of the sheet being 65 lbs in the warp direction and 48.3 lbs in the weft direction. All of these results indicate that the invented sheet is durable while both lightweight and breathable.

In the foregoing specification, specific embodiments have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present teachings.

The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.

Unless stated otherwise, terms such as “first” and “second” are used to arbitrarily distinguish between the elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements.

Unless otherwise stated, conditional languages such as “can”, “could”, “will”, “might”, or “may” are understood within the context as used in general to convey that certain embodiments include, while other embodiments do not include, certain features and/or elements. Thus, such conditional languages are not generally intended to imply that features and/or elements are in any way required for one or more embodiments.

It will be understood by those within the art that, in general, terms used herein, are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to”, the term “having” should be interpreted as “having at least”, the term “includes” should be interpreted as “includes but is not limited to”, etc.). The term “coupled” should be interpreted to include both direct and indirect coupling. 

What is claimed is:
 1. A woven sheet comprising, a first section comprising a first weave having a first grid pattern; and a second section comprising a second weave having a second grid pattern, the second section is coupled to the first section; wherein an area of first section is greater than an area of the second section; wherein the first grid pattern is less dense than the second grid pattern; wherein the first weave contributes most to an air permeability characteristic of the woven sheet; and wherein the second weave contributes most to a durability characteristic of the woven sheet.
 2. The woven sheet of claim 1, wherein the second weave is a plain weave.
 3. The woven sheet of claim 2, wherein the second grid pattern is a 1-by-1 grid pattern.
 4. The woven sheet of claim 1, wherein the first weave is a dobby weave.
 5. The woven sheet of claim 4, wherein the first pattern is a 2-by-2 grid pattern.
 6. The woven sheet of claim 1, wherein the air permeability characteristic of the first section is about 304 cubic feet per minute or greater.
 7. The woven sheet of claim 1, wherein a weight characteristic of the woven sheet is about 85 grams per square meter or less.
 8. The woven sheet of claim 1, wherein the first section comprises a first geometric pattern and a second geometric pattern.
 9. The woven sheet of claim 1, wherein the first section and the second section are directly connected.
 10. The woven sheet of claim 1, wherein the first section and the second section comprise a lyocell fiber.
 11. A woven sheet comprising: a first section having a 2-by-2 dobby weave; and a second section having a 1-by-1 plain weave, the first section contacting the second section, wherein an area of first section is greater than an area of the second section; and wherein the first section and the second section both comprise a lyocell fiber.
 12. A method of making a woven sheet, the method comprising the steps of: weaving a first section using a first weave having a first grid pattern; and weaving a second section using a second weave having a second grid pattern, the second section coupled to the first section; wherein an area of first section is greater than an area of the second section; wherein the first grid pattern is less dense than the second grid pattern; wherein the first weave contributes most to an air permeability characteristic of the woven sheet; and wherein the second weave contributes most to a durability characteristic of the woven sheet.
 13. The method of claim 12, wherein the second weave is a plain weave.
 14. The method of claim 13, wherein the second grid pattern is a 1-by-1 grid pattern.
 15. The method of claim 12, wherein the first weave is a dobby weave.
 16. The method of claim 15, wherein the first pattern is a 2-by-2 grid pattern.
 17. The method of claim 12, wherein the air permeability characteristic is equal or greater than about 304 cubic feet per minute.
 18. The method of claim 12, wherein a weight characteristic of the woven sheet is equal or less than about 85 grams per square meter.
 19. The method of claim 12, wherein the first section comprises a first geometric pattern and a second geometric pattern.
 20. The method of claim 12, wherein the first section and the second section are connected directly.
 21. The method of claim 12, wherein the first section and the second section comprise a lyocell fiber. 